Hardened fiber optic connectors having a mechanical splice connector assembly

ABSTRACT

Hardened fiber optic connectors having a mechanical splice assembly are disclosed. The mechanical splice assembly is attached to a first end of an optical waveguide such as an optical fiber of a fiber optic cable by way of a stub optical fiber, thereby connectorizing the hardened connector. In one embodiment, the hardened connector includes an inner housing having two shells for securing a tensile element of the cable and securing the mechanical splice assembly so that a ferrule assembly may translate. Further assembly of the hardened connector has the inner housing fitting into a shroud of the hardened connector. The shroud aides in mating the hardened connector with a complimentary device and the shroud may have any suitable configuration. The hardened connector may also include features for fiber buckling, sealing, cable strain relief or a pre-assembly for ease of installation.

PRIORITY

This application is a continuation of International Application No.PCT/US2017/13164, filed on Jan. 12, 2017, which claims the benefit ofpriority under 35 U.S.C. §119 to U.S. Provisional Application Ser. No.62/277,659, filed on Jan. 12, 2016, and U.S. Provisional ApplicationSer. No. 62/294,443, filed on Feb. 12, 2016, the contents of which arerelied upon and incorporated herein by reference in their entirety.

FIELD

The disclosure is directed to hardened fiber optic connectors having amechanical splice connector assembly. The hardened connectors are usefulfor optical communication as a portion of a cable assembly having anoptical waveguide.

BACKGROUND

Communication networks are used to transport a variety of signals suchas voice, video, data transmission, and the like. As communicationnetworks upgrade to increase bandwidth to the subscriber, thetransmission of signals using optical waveguides is commonly used.

Since these last mile deployments to the subscriber are typicallylocated outdoors, the network operators typically use a preconnectorizedcable assembly terminated with a hardened connector for making a quick,reliable and trouble-free optical connection to the network. Thepreconnectorized cable assembly is manufactured in a factory so that theend face of the ferrule and optical waveguides undergo a precise,multi-step polishing for maintaining a low insertion loss for theoptical connection. Examples of preconnectorized cable assembliesterminated with a hardened connector are shown in U.S. Pat. No.7,881,576 and its related applications.

However, there are instances when network operators desire to terminatehardened connectors in the field. One common way to make an opticalconnection is by fusion splicing. Fusion splicing requires that the endsof the optical fibers be precisely aligned so that the transfer theoptical signal between the ends of the optical waveguides has arelatively low-loss. But like connectors, fusion splicing requireshighly trained craftsman and special equipment to make and test theoptical connection, thereby making it a relatively expensive andinefficient proposition for field connectorization. Moreover, the actualfusion splice point is fragile and must be immobilized so it does notbend or flex. Consequently, fusion-splicing requires a splice holderthat prevents bending and stress on the splice point, which results in abulkier cable assembly and adds more time, cost and skill to theinstallation costs. For these reasons, the network operators typicallyhave not widely-deployed fusion-spliced solutions for fiber to thesubscriber applications.

Consequently, there is an unresolved need for an efficient andrelatively low-cost method of reliably making hardened opticalconnections in the field without using specialized equipment and highlyskilled labor.

BRIEF DESCRIPTION OF THE FIGS.

FIGS. 1a-1c shows a portion of a prior art the preconnectorized cableassembly terminated with a hardened connector being plugged into areceptacle.

FIG. 2 is an exploded view of the prior art preconnectorized cableassembly depicted in FIGS. 1a -1 c.

FIG. 3 shows a partially assembled perspective view of the conventionalprior art preconnectorized cable assembly of FIG. 2 having the connectorassembly attached to the optical waveguide of the cable and positionedwithin the half-shell of the hardened connector.

FIG. 4 shows the partially assembly crimp assembly being attached to thecable of the conventional prior art preconnectorized cable assembly ofFIG. 3.

FIG. 5 is a perspective view of an explanatory cable assembly comprisinga hardened connector comprising a mechanical splice connector assemblyaccording to the concepts of the present application.

FIGS. 5A and 5B respectively are partially assembled rear perspectiveview and front perspective view of the cable assembly of FIG. 5.

FIG. 6 shows a partially assembled perspective view of the hardenedconnector of FIG. 5 as part of a cable assembly showing one shell of theinner housing having a connector assembly receiving portion with anextended length cavity so the ferrule assembly of mechanical spliceconnector assembly may translate rearward as needed.

FIG. 6A shows a partially assembled perspective view of another hardenedconnector for a cable assembly similar to FIG. 5 showing one shell ofthe inner housing that receives the ferrule assembly only when the camof the mechanical splice connector assembly is in a clamping orientationwithin the extended is length cavity.

FIG. 7 is a partially exploded view of an explanatory mechanical spliceconnector assembly used in the hardened connector of FIG. 5.

FIGS. 8-15 depict steps for assembling the hardened connector of FIG. 5.

FIGS. 16 and 17 depict another fiber optic cable that may be used withthe hardened connector of FIG. 5.

FIG. 18 is a top view of another explanatory cable assembly comprising ahardened connector comprising a mechanical splice connector assemblyaccording to the concepts of the present application.

FIG. 19 is a partially exploded view of an explanatory cable assemblywith a mechanical splice connector assembly used in the hardenedconnector similar to FIG. 18.

FIG. 20 is a longitudinal sectional view of the cable assembly of FIG.19.

FIGS. 21 and 22 are perspective views of a first shell and a secondshell of the cable assembly of FIG. 19 showing internal details of theshells.

FIGS. 23A and 23B are close-up perspective views of the first shell ofFIG. 21.

FIGS. 24A and 24B are close-up perspective views of the second shell ofFIG. 22.

FIGS. 25 and 26 are close-up perspective views of a rear portion of thesecond shell and a prepared cable placed into the rear portion of thesecond shell, respectively.

FIG. 27 is a top view showing the second shell and a prepared cable withits mechanical splice connector assembly attached placed into the secondshell.

FIG. 28 is a perspective view showing the first and second shells withthe prepared cable with its mechanical splice connector assemblyattached.

FIG. 29 is a perspective view showing the first and second shellsdisposed about the prepared cable with its mechanical splice connectorassembly attached with the crimp band positioned on a rearward portionof the first and is second shells along with an optional insert disposedabout the cable.

FIG. 30 is a longitudinal sectional view showing the first and secondshells disposed about the prepared cable with its mechanical spliceconnector assembly attached and depicting a buckling zone formed by thefirst and second shells.

FIGS. 31 and 32 are close-up rear perspective views of a portion of ashroud, a cable sealing element and a pusher of FIG. 19 in anunassembled state and an assembled state, respectively.

FIG. 33 is a perspective view of another cable sealing element that maybe used with a cable having a different profile for making the connectoradaptable to other cable types.

FIGS. 34A-34C are perspective views depicting a pre-assembly of aplurality of parts, thereby allowing the user to quickly and easilyterminate a cable to the connector.

FIG. 34D is a partial sectional view of FIG. 34C showing the arrangementof the pre-assembly with a cable attached thereto.

FIG. 35 is a top view of another explanatory cable assembly similar toFIG. 18 that further includes a boot for cable bend-relief.

FIG. 36A and 36B are longitudinal sectional views of the cable assemblyof FIG. 35.

FIGS. 37A-37E are perspective views showing the assembly steps of thecable assembly of FIG. 35.

FIG. 37F is a sectional view showing the advancement of the pusher todeform the cable sealing element about the cable during assembly andstrain relieve the cable.

DETAILED DESCRIPTION

The concepts will now be described more fully hereinafter with referenceto the accompanying drawings showing preferred embodiments. The conceptsmay, however, be embodied in many different forms and should not beconstrued as limited to the embodiments set forth herein; rather, theseembodiments are provided so that the disclosure will fully convey thescope of the concepts to those skilled in the art. The drawing are notnecessarily drawn to scale but are configured to clearly illustrate theconcepts.

The present application is directed to hardened optical connectorshaving a mechanical splice connector assembly. The mechanical spliceconnector assembly has a stub fiber that is mechanically spliced to anoptical fiber of a cable (i.e., a field-fiber) by the user such as inthe field. The mechanical splice connector assembly also includes othercomponents for actuating and securing a mechanical splice between thestub fiber and the field fiber. Conventional prior art hardenedconnectors used connector assemblies that were attached directly to theoptical waveguide of a fiber optic cable in a factory making them thenready for termination without further preparation by the user.

However, preconnectorized cable assembly 10 has some perceiveddisadvantages over factory prepared solutions such as coming inpredetermined lengths and stocking and availability of several differentlengths for installation. Thus, in many installations a longerpreconnectorized cable assembly is selected and installed with the slacklength of the cable of the preconnectorized cable assembly being eitherstored in a suitable manner such as a slack loop or the end of the cableis cut to length and the excess cable is thrown away. Many networkoperators would like to use bulk cable and install the hardenedconnector in the field to avoid the issues of slack storage or cuttingthe preconnectorized cable assembly to length and throwing away theexcess. Thus, the concepts disclosed herein are advantageous over theprior art.

FIGS. 1a-1c show the various stages during the mating of a hardenedconnector of the conventional prior art preconnectorized cable assembly10 with a complimentary receptacle 30. Unlike the concepts of thepresent application, the preconnectorized cable assembly 10 of the priorart does not provide a field-installable solution for the networkoperator, but instead is a factory terminated solution. A more detailedview of the prior art is preconnectorized cable assembly 10 is providedwith reference to FIGS. 1-4 before turning toward a more detailedexplanation of the concepts disclosed herein.

Specifically, FIG. 1a shows receptacle 30 detached from preconnectorizedcable assembly 10. Moreover, preconnectorized assembly cable 10 andreceptacle 30 are depicted with their respective protective caps on.Protective cap 6 is used for shielding a conventional connector assembly5, and in particular, the end face of a connector ferrule 5 b from theelements and/or damage. Specifically, installed protective cap 6isolates connector ferrule 5 b from the elements and prevents it frombeing damaged during transportation and handling. FIG. 1b showsprotective cap 6 removed from the end of the hardened connectorpreconnectorized cable assembly 10. Likewise, the respective cap ofreceptacle 30 is also removed. Preconnectorized cable assembly 10 ispositioned to engage the complimentary portions of receptacle 30.Specifically, alignment indicia 8 of preconnectorized cable assembly 10is positioned to its complementary indicia 30 c of receptacle 30. FIG.1c shows a mated connection between the preconnectorized cable assembly10 and receptacle 30, thereby making an optical connection therebetween.This factory prepared cable assembly 10 does not require specialequipment, training, or skill is required to make the opticalconnection. Thus, the labor cost of deploying the optical network to thepremises is cost effective and efficient, but it does not provide theflexibility for the user on cable length.

FIGS. 2-4 show further details of the conventional prior artpreconnectorized cable assembly 10. FIG. 2 depicts an exploded view ofconventional preconnectorized cable assembly 10 showing cable 40′ asdisclosed in U.S. Pat. No. 6,542,674 and the components of conventionalhardened connector 50. Cable 40′ is disclosed with an optional toninglobe, but other cables are possible. As best shown in FIG. 3, the priorart hardened connector 50 includes an industry standard SC typeconnector assembly 52 having a connector body 52 a, a ferrule 52 b in aferrule holder (not numbered), is a spring 52 c, and a spring push 52 d.Hardened connector 50 also includes a crimp assembly (not numbered) thatincludes a crimp housing having at least one half-shell 55 a and a crimpband 54, a shroud 60 having an O-ring 59, a coupling nut 64, a cableboot 66, a heat shrink tube 67, and a protective cap 68 secured to boot66 by a wire assembly 69.

FIGS. 3 and 4 depict partially assembled portions of conventional priorart preconnectorized cable assembly 10 showing the process of attachingthe crimp assembly to cable 40′. FIG. 3 shows cable 40′ having strengthmembers 45 (not visible) cut flush with the stripped back jacket 48,thereby exposing the two GRP strength components 44 and opticalcomponent 42 from the end of cable 40′. The conventional connectorassembly 52 can then be attached to the optical waveguide using anadhesive for securing the ferrule 52 b to the optical waveguide beforecleaving and polishing the ferrule/optical waveguide in the factoryassembly process.

FIG. 5 is a perspective view of a cable assembly 100 comprising ahardened connector 150 comprising a mechanical splice connector assembly152 according to the concepts of the present application. Hardenedconnector 150 is similar to the hardened connector shown in FIGS. 1-4,but uses a mechanical splice connector assembly 152 (FIG. 7) so thecraft may terminate the hardened connector in the field such as on anend of a bulk cable. FIG. 5 depicts an assembled hardened connector 150terminated to a fiber optic cable 140, which is similar to the fiberoptic cable 40′.

Although hardened connector 150 is depicted as having a package with anOptiTap® connector footprint such as available from Corning OpticalCommunications LLC of Hickory, N.C. to explain the concepts, theconcepts disclosed may have a package that uses any suitable hardenedconnector footprint such as a DLX footprint or a FastConnect footprintas desired by using different components for the hardened connectorinterface/package. FIGS. 5A and 5B respectively are partially-assembledrear perspective view and front perspective view of the cable assembly100 of FIG. 5.

FIG. 6 shows a partially assembled perspective view of the hardenedconnector 150 as part of cable assembly 100 showing one shell 155 a ofan inner housing 155 formed by two shells (i.e., the two shells are thesame part, but could be configured as two different parts) having aconnector assembly receiving portion with an extended length cavity157EC so the ferrule assembly of mechanical splice connector assemblymay translate rearward as needed.

The inner housing 155 with the connector assembly receiving portion 157with the extended length that is sized so that the ferrule assembly of170 of the mechanical splice connector assembly 152 has an extendedrearward cavity so the ferrule assembly 170 has a space to translatewhen in an unmated state. The extended length cavity 157EC of theconnector assembly receiving portion also provides a longer length forany buckling of the field optical waveguide 146 that may occur duringtranslation upon mating with a complimentary device.

With continuing reference to FIG. 6, shell 155 a includes a first end155 b with a cavity for securing the mechanical splice connectorassembly 152 and a second end 155 c with a cavity and shape that aids insecuring the cable 140 and provides strain relief. Additionally, shell155 a includes a cable clamping portion at second end 155 c and aconnector assembly receiving portion 157 at first end 155 b. Asdepicted, the connector assembly receiving portion 157 generallyconforms with the profile of the mechanical splice connector assembly152, but the connector assembly receiving portion with an extendedlength cavity 157EC at the rear allows for rearward movement of theferrule assembly of the mechanical splice connector assembly as neededwhen mated with a complimentary device or connector.

FIG. 6A shows a partially assembled perspective view of another hardenedconnector for a cable assembly similar to FIG. 5 showing one shell 155a′ of the inner housing that receives the ferrule assembly only when thecam 158 of the mechanical splice connector assembly 152 is in a clampingorientation within the extended length cavity 157EC. By allowing the cam158 of mechanical is splice connector to fit into the extended lengthcavity 157EC only when in the clamping position, it reduces the riskthat the hardened connector is not assembled correctly by the user.

As best shown in FIG. 12, the inner housing 155 of the hardenedconnector 150 may be secured by a crimp band 154, but other suitableconstructions are possible such as using an adhesive or the like. Inthis embodiment, inner housing 155 comprises two half-shells 155 a thatare held together by crimp band 154 once the cable assembly 100 havingthe hardened connector 150 is assembled. Inner housing 155 is configuredfor securing mechanical splice connector assembly 52 as well asproviding strain relief to cable 140. The inner housing 155 may securethe connector body 152 a of mechanical splice connector assembly 150 inany suitable manner and allow the ferrule assembly 170 to translateaccording to the concepts disclosed.

Although, the term half-shell is used, it is to be understood that itmeans suitable shells and includes shells that are greater than or lessthan half of the inner housing formed by shells 155 a. Crimp band 154 ispreferably made from brass, but other suitable crimpable materials maybe used. This advantageously results in a relatively compact connectorarrangement using fewer components. Moreover, the crimp band 154 allowsthe craft to assemble hardened connector 150 to cable 140 to beassembled quickly and easily in a familiar manner. Of course, otherembodiments are possible according to the concepts disclosed such asusing an adhesive for securing the shells together.

A longitudinal axis A-A is formed between first end 155 b and second end155 c near the center of inner housing 155, through which a portion of alongitudinal passage is formed. When assembled, optical fiber 146 ofcable 140 passes through the longitudinal passage and enters themechanical splice connector assembly 152 for abutting the stub fiber 152c held in a bore of ferrule 152 b.

In this embodiment, cable clamping portion 156 has two outboardhalf-pipe passageways 156 a and a central half-pipe passageway 156 bthat is generally disposed along longitudinal axis A-A. Half-pipepassageways 156 a and 156 b preferably include at least one rib 156 cfor securely gripping or clamping optical component 142 and strengthcomponents 144 of cable 140 after crimp band 154 is crimped, therebysecuring the components. Although, half-pipe passageways 156 a and 156 bare sized for the components of cable 140, the passageways can be sizedfor different cable configurations. Likewise, half-shell 155 a has aconnector assembly receiving portion 157 that is sized for attachingconnector assembly 152. Specifically, connector assembly receivingportion 157 has a half-pipe passageway 157 a that opens into andconnects central half-pipe passageway 156 b and a partially rectangularpassageway for accommodating the connector housing. Half-pipe passagewayis sized for securing components of the mechanical splice connectorassembly 152. Rectangular passageway 157 b receives a portion ofconnector body 152 a therein and inhibits the rotation between connectorassembly 152 and the inner housing 155. The inner housing 155 with theconnector assembly receiving portion comprising extended length cavity157EC may be sized for any suitable mechanical splice connector assemblysuch as an SC mechanical splice connector assembly similar to theOptiSnap® available from Corning Optical Communications LLC; however,any suitable mechanical splice connector assembly may be used such asLC, ST, FC, MT or the like.

FIG. 7 is a partially exploded view of an explanatory mechanical spliceconnector assembly 152 comprising a ferrule assembly 170 having a stuboptical fiber 152 c secured to a ferrule 152 b that is used in hardenedconnector 150. Mechanical splice connector assemblies can have differentdesigns, configurations and/or components for making a mechanical splicebetween a stub optical fiber secured to a ferrule and the field opticalfiber inserted into the hardened connector 150.

In this embodiment, mechanical splice connector assembly 152 comprises aconnector body 152 a and a ferrule assembly 170. Ferrule assembly 170comprises a ferrule 152 b having a stub fiber 152 c secured is theretoand extending from the rear. The end face of the ferrule 152 b and thefiber end are factory polished and the stub fiber 152 c is used formaking a mechanical splice with a field fiber that is inserted into themechanical splice connector assembly 152 by the user. Alignment of thestub fiber 152 c and the field fiber is accomplished using splicecomponents 153 that are inserted into ferrule holder 154. The ferruleassembly of the mechanical splice connector assembly may use anysuitable actuation member for aligning and securing the one or moresplice components. Typically, the actuation member is moved from an openposition for inserting the field optical fiber to a clamping positionfor aligning and securing the field optical fiber with the stub opticalfiber. Actuation members may be one or more clamps, wedges, cams or thelike for pushing the one or more splice components together for clampingthe stub fiber in alignment with the field fiber for opticalcommunication therebetween.

As depicted in the explanatory embodiment, a cam 158 having an eccentricprofile on the through passageway is used for pushing the splicecomponents 153 together after a field fiber is inserted into and alignedwith the mechanical splice connector assembly 152. The mechanical spliceconnector assembly may also include a lead-in tube 151, a spring 156, aspring push 157 and a heat shrink (not numbered) for securing the fiberto the connector assembly as desired.

FIGS. 8-15 depict steps for assembling the hardened connector 150 oncable 140. FIG. 8 shows portions of hardened connector 150 slid onto thecable 140. Specifically, a crimp band 154, a shroud 160 having one ormore O-rings 159, a coupling nut 164, a cable boot 166, and a heatshrink tube 167 are slid onto cable 140 as shown. Portions may bepreassembled to simply installation for the user. For instance, theshroud 160, coupling nut 164, O-rings 159 and heat shrink tube 167 maybe preassembled so that the user can easily slide the pre-assembledcomponents onto the cable 140.

FIG. 9 depicts cable 140 prepared for termination by hardened connector150 by stripping the cable jacket and cleaving the optical fiber. Inthis embodiment, cable 140 is a flat dielectric cable having an opticalcomponent 142 such as a buffer tube, at least one strength component144, and a jacket 148. In this cable, strength components 144 are twoglass-reinforced plastic (GRP) strength components and optical component142 has an optical waveguide 146 disposed within a buffer tube 143.Cable 140 may also optionally include other components such as strengthmembers to provide additional tensile strength, ripcords, toningelement, etc. as desired. As used herein, the term “strength component”means the strength element has anti-bucking strength, while the term“strength member” means a strength element lacks anti-buckling strength.Furthermore, the term “tensile element” means either a strengthcomponent or a strength member. Cable 40 is an all-dielectric design,but other cables having conductive components such as steel strengthcomponents may be used with the disclosed concepts. Of course, othercables may be used with the concepts of the present invention. Moreover,other suitable mechanical splice connector assemblies may be used withsuitable cables according to the concepts of the present invention,thereby resulting in numerous cable/connector combinations.

Cable 140 is prepared so that the optical waveguide 146, opticalcomponent 142, and strength components 144 extend a suitable lengthbeyond the end of cable jacket 148 as shown in FIG. 9.

FIG. 10 depicts the optical waveguide 146 attached to the mechanicalsplice connector assembly 152. The cleaved optical waveguide 146 isinserted into the lead-in tube 155 of the mechanical splice connectorassembly 152 until the optical waveguide 146 abuts the stub opticalfiber 152 c. Once properly aligned and positioned, the user can activatethe splice assembly by rotating cam 158 in this embodiment of themechanical splice connector assembly 152. Tools are available that canhelp the uninitiated attach a mechanical splice connector. By way ofexample, a user may use a Pretium OptiSnap installation tool to verifythe optical performance of the mechanical is splice. Some mechanicalsplice connector assemblies may have one or more translucent componentssuch as a translucent splice parts 153, ferrule holder 154 and/or cam158 for verifying the continuity of the splice. By way of explanation, aVFL tool launches visible light into the mechanical splice and when thevisible light excessively scatters the light is leaking from themechanical splice; however, when the glow diminishes the mechanicalsplice between the stub fiber and field-fiber is transmitting light atthe splice point indicating a quality connection and lower splice lossesat which point the mechanical splice may be secured.

FIG. 11 depicts the assembly of FIG. 10 having mechanical spliceconnector assembly 152 and cable 140 positioned in a first shell 155 aof hardened connector 150. The alignment of the two shells 155 a isaccomplished by inserting pins 157 c into complementary bores 157 dbetween the two shells. FIG. 12 shows both shells 155 a of inner housing155 disposed about cable 140 before crimp band 154 is installed bydeforming the crimp band 154 about inner housing 155. FIG. 12a depictsthe connector body 152 a secured to inner housing 155 for inhibitingmovement of the same. In this embodiment, inner housing comprises aplurality of latches 155L that cooperate with complimentary openings(not numbered) on connector body 152 a. More specifically, each shell155 a comprises a latch 155L and the connector body 152 a has openingson opposite sides for securing the connector housing as shown, but otherconstructions are possible for securing the connector body 152 a withthe inner housing 155.

Crimp band 154 provides a robust attachment, but other attachment meanscould alternatively be used or additionally be used. For instance,shells may include one or more bores (not visible) that lead to one ofhalf-pipe passageways 156 a or 156 b. Bores allow for inserting anadhesive, epoxy or the like into the inner housing 155, therebyproviding a secure connection for strain relief.

Shells 155 a may be symmetric only requiring one component or differentright and left shells may be used as desired. FIG. 6 shows the innersurface of one shell 155 a. In this case, only one shell 155 a is usedsince the same symmetrical shells are used for both portions of innerhousing 155. In other embodiments there may be a first shell and asecond shell, which are different. For instance, one shell may have allof the alignment pins, rather than each shell having both alignment pinsand bores.

After the inner housing 155 is attached to the sub-assembly of FIG. 10,the inner housing assembly may mate with any suitable hardened connectorpackage such as shroud 160. Shroud 160, coupling nut 164 and heat shrink167 that were previously threaded onto cable 140 may be slid forward sothat the inner housing is at least partially disposed in shroud 160 asshown in FIG. 13. Thereafter, the heat shrink may be applied forweatherproofing as shown in FIG. 14.

Additionally, inner housing 155 is keyed to direct the insertion of theassembly into shroud 160 as best shown in FIG. 5B. In this case, shells155 a include planar surfaces 157 e (FIG. 6) on opposites sides of innerhousing 155 at a first end 155 b to inhibit relative rotation betweeninner housing 155 and shroud 160. In other embodiments, the innerhousing may be keyed to the shroud using other configurations such as acomplementary protrusion/groove or the like.

The hardened connector may optionally include other components asdesired. By way of example, any suitable means may be used for retainingthe coupling nut 164 in a forward position on the shroud 160 while stillallowing rotation. For instance, a detent, snap ring or the like may beused for retaining the coupling nut to the shroud. FIG. 14A depicts asnap ring 163 disposed on a portion of the shroud 160. For instance,snap ring 163 may be disposed in a groove (not numbered) disposed on aportion of shroud 160 when assembled for seating the snap ring 163. Snapring 163 may simplifying the assembly of the connector by allowing thesliding the coupling nut 164 over the shroud 160 until snap ring 163seats in the groove to secure the coupling nut 164 while is stillallowing rotation about the shroud 160. Other embodiments may use alanyard for a protective dust cap or the like for keeping the couplingnut 164 in a forward position. Further, components of the hardenedconnector pre-assembled for simplifying assembly of the hardenedconnector by the user. As depicted in FIG. 14B, one or more O-rings 159and snap ring 163 are preassembled to the shroud 160. Pre-assembling thesnap ring 163 with the shroud 160 also allows the coupling nut 164 andheat shrink 167 to be pre-assembled for easing final assembly of thehardened connector by user.

Returning to FIG. 13, shroud 160 has a generally cylindrical shape witha first end 160 a and a second end 160 b. Shroud generally protectsfront end of mechanical splice connector assembly 152 and in preferredembodiments also keys hardened connector 150 with the respective matingreceptacle or device. Moreover, shroud 160 includes a through passagewaybetween first and second ends 160 a and 160 b. As discussed, thepassageway of shroud 160 is keyed so that inner housing 155 is inhibitedfrom rotating when hardened connector 150 is assembled. Additionally,the passageway may have an internal shoulder (not numbered) thatinhibits the inner housing from being inserted beyond a predeterminedposition.

First end 160 a of shroud 160 includes at least one opening (notnumbered) defined by shroud 160. The at least one opening extends from amedial portion of shroud 160 to first end 160 a. In this case, shroud160 includes a pair of openings on opposite sides of first end 160 a,thereby defining alignment portions or fingers 161 a,161 b. In additionto aligning shroud 160 with receptacle during mating, alignment fingers161 a,161 b may extend slightly beyond the ferrule end of mechanicalsplice connector assembly 152, thereby protecting the same. As shown,alignment fingers 161 a,161 b may have different shapes so hardenedconnector 150 and its complimentary device 30 only mate in oneorientation. In preferred embodiments, this orientation is marked onshroud 160 using alignment indicia 160 c so that the craftsman canquickly and easily mate the hardened connector. In this case, alignmentindicia 160 c is an arrow molded into the top alignment finger of shroud160, however, other suitable indicia may be used. Then, the arrow may bealigned with complimentary alignment indicia disposed on thecomplimentary device so that alignment fingers 161 a,161 b have theproper orientation during mating. Thereafter, the craftsman engages theexternal threads of coupling nut 164 with the complimentary internalthreads for making the optical connection.

As depicted in FIGS. 5A and 10, a major axis of the fiber optic cable140 is arranged in a generally vertical orientation with respect to thelongitudinal symmetrical plane of mechanical splice connector assembly152. The major axis of fiber optic cable 140 is also oriented togenerally pass through the alignment portions or fingers 161 a,161 b ofshroud 160. Inner housing 155 may have a round portion at the rearportion 155 r and is keyed at a front portion 155 f to allow rotation ofthe inner housing 155 when locating the proper keying to shroud 160.FIG. 5B depicts the complementary protrusion 155 p of inner housing 155engaging the respective groove 169 of the shroud 160 for orienting themechanical splice connector assembly 152 with the different shapedalignment fingers 161 a, 161 b of shroud 160.

In this case, the mating between the hardened connector and thereceptacle is secured using a threaded engagement, but other suitablemeans of securing the optical connection are possible for other hardenedpackages. For instance, the securing means for the hardened connectormay use a quarter-turn lock, a quick release, a push-pull latch, or abayonet configuration as desired.

A medial portion of shroud 160 has one or more groove (not numbered) forseating one or more O-rings 159. O-ring 159 provides a weatherproof sealbetween hardened connector 150 and a complimentary device such as areceptacle or protective cap. The medial portion also includes ashoulder 160 d that provides a forward stop for coupling nut 164.Coupling nut 164 has a passageway sized so that it fits over the secondend 160 b of shroud 160 and is easily rotates about the medial portionof shroud 160. In other words, coupling nut 164 cannot move beyondshoulder 160 d, but coupling nut 64 is able to rotate with respect toshroud 60. Second end 160 b of shroud 160 may also include a steppeddown portion having a relatively wide groove. This stepped down portionand groove may be used for securing heat shrink tubing 167. Heat shrinktubing 167 is used for weatherproofing the hardened connector to thecable.

After the heat shrink tubing 167 is attached, boot 166 is slid over heatshrink tubing 67 and a portion of shroud 160 as shown in FIG. 15. Boot166 is preferably formed from a flexible material such as KRAYTON. Heatshrink tubing 167 and boot 166 provide bending strain relief to thecable near hardened connector 150. Boot 166 has a longitudinalpassageway (not visible) with a stepped profile therethrough. The firstend of the boot passageway is sized to fit over the second end of shroud160 and heat shrink tubing 167. The first end of the boot passageway hasa stepped down portion sized for cable 140.

Generally speaking, most of the components of hardened connector 150 areformed from a suitable polymer. Preferably, the polymer is a UVstabilized polymer such as ULTEM 2210 available from Sabic; however,other suitable materials are possible. For instance, stainless steel orany other suitable metal may be used for various components.

The described explanatory embodiment provides an optical connection thatcan easily be made in the field by the user. Additionally, the opticalconnection of the hardened connector 150 is easily connected ordisconnected by merely mating or unmating the hardened connector 150with the respective receptacle or other device by threadly engaging ordisengageing coupling nut 164. Thus, the hardened connector of thepresent application allow deployment of optical waveguides toward thesubscriber or other locations in an easy and economical manner, withouthaving to store cable slack or cut and throw away cable. Furthermore,the concepts disclosed may be practiced with is other fiber opticcables, connectors and/or other mechanical splice connector assemblyconfigurations.

By way of example, FIGS. 16 and 17 depict another fiber optic cable 140′that may be used with the hardened connector 150. Specifically, FIG. 16shows a cable 140′ prepared for connectorization and FIG. 17 showsstrength members 143 such as aramid yarns being positioned about outerbarrel 155 o of inner housing 155 before installing crimp band 154. Ofcourse other techniques are possible for securing strength members 143,but using this technique allows one configuration of inner housing 151to accommodate several different types of cables. Thereafter, theassembly of hardened connector 150 is completed in a similar manner asdisclosed herein.

Hardened connectors may also terminate more than one optical waveguide.A plurality of optical waveguide can be arranged loosely, disposed in aribbon, or bundlized. For instance, a cable may have more than oneoptical waveguide therein. An inner housing suitable for securing morethan one mechanical splice connector assembly is possible. Likewise, theshells of inner housing may be non-symmetrical to handle other cabledesigns. Furthermore, inner housings may hold one or more multi-fiberferrules.

Additionally, the hardened connectors may also have electrical powercomponents that are connected and disconnected through the hardenedconnector.

Still other variations of hardened connectors are possible according tothe concepts disclosed herein. By way of explanation, hardenedconnectors may also include features for influencing the location offiber bow or buckling when the ferrule assembly of the mechanical spliceconnector assembly moves rearward. Hardened connectors may also includefeatures or components for sealing the cable to the connector orproviding cable strain relief. Still further, hardened connectors maycomprise a pre-assembly of components for ease ofinstallation/termination of the hardened connector by the user.

FIG. 18 depicts is a top view of another explanatory cable assembly 100′is similar to cable assembly 100. Cable assembly 100′ comprises anotherhardened connector 150 comprising a mechanical splice connector assembly152 (not visible in FIG. 18) that is similar the hardened connector 150of FIG. 5 using some similar components, but also uses some differentcomponents. Like the hardened connector 150 of FIG. 5, the hardenedconnector 150 of FIG. 18 allows the user to terminate the hardenedconnector 150 in the field such as on an end of a bulk cable such ascable 140 for providing a tailored cable length for the cable assembly.Moreover, the hardened connector of FIG. 18 allows the user theflexibility of using other fiber optic cable designs with the connectoras desired by changing one or more components or termination techniques.

FIG. 19 is a partially exploded view of an explanatory cable assembly100′ similar to FIG. 18 comprising hardened connector 150 with amechanical splice connector assembly 152 similar to the mechanicalsplice connector assembly shown in FIG. 7. Cable assembly 100′ alsocomprises fiber optic cable 140 that can be terminated to mechanicalsplice connector assembly 152 by a user in the field. However, thehardened connector 150 is adaptable for use with other cables asdesired.

Hardened connector 150 of FIG. 19 comprises an inner housing 255 that issimilar to inner housing 155. Inner housing 255 comprises at least twoshells 255 a,255 b having a longitudinal passageway (not numbered) forpassing at least one optical waveguide 12 therethrough from a first end155 b to a second end 155 c, at least one cable clamping portion atsecond end 155 c, and a connector assembly receiving portion 157 at afirst end 155 b, and the connector assembly receiving portion 157comprises an extended length cavity 157EC. The connector assemblyreceiving portion 157 generally conforms with the profile of themechanical splice connector assembly 152, and the connector assemblyreceiving portion 157 has an extended length cavity 157EC at the rearallowing for rearward movement of the ferrule assembly 170 of themechanical splice connector assembly as discussed herein. Hardenedconnector 150 also comprises mechanical splice connector assembly 152.Mechanical splice connector assembly 152 comprises connector body 152 aand a ferrule assembly 170 having stub optical fiber 152 c secured toferrule 152 b and may have any suitable configuration as discussed.

When assembled, a portion of the mechanical splice connector assembly152 is secured to the inner housing 255 so that the ferrule assembly 170of the mechanical splice connector assembly 152 can move rearward intothe extended length cavity 257EC when displaced rearward such as duringmating with a complimentary connector. Mechanical splice connectorassembly 152 may include the other features/components as discussedherein.

Hardened connector 150 of FIG. 19 also comprises a crimp band 154 forholding the two shells 255 a,255 b together when assembled, a shroud 260similar to shroud 160, a coupling nut 164, a cable sealing element 210,a pusher 220, a rear nut 230 and a cable bend relief 240. However, otherembodiments of hardened connector 150 are possible and may use fewer ormore components as desired. Other variations of the components for thehardened connector 150 are also possible according to the conceptsdisclosed. By way of explanation, hardened connectors 150 may use othercable sealing elements for different cable types or profiles.

FIG. 20 is a longitudinal sectional view of the cable assembly 100′depicted in an assembled state. As depicted, first shell 255 a andsecond shell 255 b cooperate to form a bow zone BZ along thelongitudinal passage formed by inner housing 255. More specifically,first shell 255 a comprises a bow geometry BG for aiding the initiationof a bow in the optical waveguide 146 as needed, and second shell 255 bcomprises a bow cavity BC for providing a space for the bow in opticalwaveguide 146 to occupy. Inner housing 255 also includes an extendedlength cavity 257EC at the rear allowing for rearward movement of theferrule assembly 170 of the mechanical splice connector assembly 152.Further, cam 158 of mechanical splice connector 152 may be allowed toonly fit into the extended length cavity 157EC only when in the isclamping position for securing the optical waveguide 146, therebyreducing the risk that the hardened connector 150 is not assembledcorrectly by the user.

Bow zone BZ provides a suitable cavity for an optical waveguide 146 offiber optic cable 140 to bow and move without making significant contactwith an inner surface of the longitudinal passageway of inner housing255. Further, the bow zone BZ can provide a slight pre-bow forinfluencing the location of the bow and the bow profile as the opticalwaveguide 146 as the ferrule assembly of the mechanical splice connectorassembly moves rearward during mating. Consequently, the opticalperformance of the optical waveguide 146 may be preserved. By way ofexample, the bow zone BZ may have a length in the range of 15-22millimeters, but other lengths may be possible as well.

By way of explanation, first shell 255 a comprises a bow geometry BGwith a profile designed to initiate a bow in the optical waveguide 146when in the relaxed state to influence the formation of the fiber bow,and second shell 255 b comprises a bow cavity BC for providing a spacefor the fiber bow to occupy without having undue contact with thelongitudinal passageway of inner housing 255. For instance, the bowgeometry BG may be a bow ramp that projects toward the longitudinal axisA-A of the inner housing for initiating a bow in optical waveguide 146.In one explanatory embodiment, the bow ramp extends to the longitudinalaxis A-A of the inner housing 255. Further, the bow ramp may becurvilinear so that no sharp surfaces are present.

FIGS. 21 and 22 are perspective views of first shell 255 a and secondshell 255 b showing internal details of the respective shells. FIGS. 23Aand 23B are close-up perspective views of the first shell 255 a andFIGS. 24A and 24B are close-up perspective views of the second shell 255b. With continuing reference to FIGS. 21 and 22, shells 255 a,255 binclude respective first ends 155 b with cavity for securing themechanical splice connector assembly 152 and respective second ends 155c with a cavity and shape that aids in securing the cable 140 and forproviding strain relief to the cable when assembled. Specifically,shells 255 a,255 b comprise a cable clamping portion at second is ends155 c and connector assembly receiving portions 157 at first ends 155 b.As depicted, the connector assembly receiving portion 157 generallyconforms with the profile of the mechanical splice connector assembly152, but the connector assembly receiving portion with an extendedlength cavity 157EC at the rear allows for rearward movement of theferrule assembly of the mechanical splice connector assembly 152 asneeded when mated with a complementary connector.

Inner housing 255 may comprise one or more latches 255R (FIG. 21) thatcooperate with complimentary openings or features (not numbered) onconnector body 152 a. More specifically, shells 255 a each comprise alatch 255R and the connector body 152 a has openings on opposite sidesfor securing the connector housing as best shown in FIG. 28, but otherconstructions are possible for securing the connector body 152 a withthe inner housing 255.

FIGS. 25 and 26 are close-up perspective views of a rear portion of thesecond shell 255 a and a prepared cable 140 placed into the rear portionof the second shell, respectively. Shells may have any suitableshape/geometry to accommodate the desired cable configuration. In thisembodiment, cable clamping portion 156 has two outboard half-pipepassageways 156 a and a central half-pipe passageway 156 b that isgenerally disposed adjacent to longitudinal axis A-A. Half-pipepassageways 156 a and 156 b may include at least one rib (not visible)for securely gripping or clamping optical component 142 and strengthcomponents 144 of cable 140 after crimp band 154 is crimped, therebysecuring the components. Although, half-pipe passageways 156 a and 156 bare sized for the components of cable 140, the passageways can be sizedfor different cable configurations. Likewise, shells 255 a,255 bcomprises connector assembly receiving portion 157 that is sized forattaching connector assembly 152 as discussed herein. The inner housing255 with the connector assembly receiving portion comprising extendedlength cavity 157EC may be sized for any suitable mechanical spliceconnector assembly and may be used with multifiber mechanical spliceconnector assemblies as desired.

FIG. 27 is a top view showing a partially assembled hardened connector150 having the second shell 255 b and a prepared fiber optic cable 140with its mechanical splice connector assembly 140 attached placed intothe second shell. The shells 255 a, 255 b of the inner housing 255 maybe configured to receive the ferrule assembly only when the cam 158 ofthe mechanical splice connector assembly 152 is in a clampingorientation within the extended length cavity 157EC. By allowing the cam158 of mechanical splice connector to fit into the extended lengthcavity 157EC only when in the clamping position, it reduces the riskthat the hardened connector is not assembled correctly by the user.Longitudinal axis A-A is formed between first end 155 b and second end155 c near the center of inner housing 255, through which a portion of alongitudinal passage is formed. When assembled as best shown in FIG. 26,optical fiber 146 of cable 140 passes through the longitudinal passageand enters the mechanical splice connector assembly 152 for abutting thestub fiber 152 c held in a bore of ferrule 152 b.

FIG. 28 is a perspective view showing the first shell 255 a holding theprepared cable 140 with its mechanical splice connector assembly 152attached and ready to have second shell 255 b placed upon about thesub-assembly. As depicted, the connector body 152 a is secured to thefirst shell 255 a by latches 255R. As second shell 255 b is aligned andplaced onto first shell 255 a, alignment arms 255AA of second shellscooperate with alignment channels 255AC for securing the respectivefirst ends 155 b of the shells 255 a,255 b (best shown in FIGS. 23B and24B). When the shells 255 a,255 b are placed together a small gap G(Fig.37C) exists between the shells at a rear portion so that the shellscan be pushed together and clamp onto the tensile elements 144 such asglass-reinforced plastic (GRP) members for strain-relieving the cable140 to the inner housing 255.

FIG. 29 is a perspective view showing the first shell 255 a and secondshells 255 b disposed about the prepared cable 140 and the crimp band154 is (which was previously threaded onto cable 140) positioned on arearward portion of the inner housing 255 before being crimped forsecuring the shells.

FIG. 30 is a longitudinal sectional view showing the first and secondshells 255 a,255 b disposed about the prepared cable 140 and depictingthe bow zone BZ. FIG. 30 also depicts a portion of a transverse bore Bformed by shells 255 a, 255 b (also see FIG. 29). Transverse bore B actsas a demarcation location for the optical waveguide 146 as it passesinto the bow zone BZ. The transverse bore b also provides a flexlocation for the cable clamping region for the inner housing 255 wherethe crimp band 154 may deflect rearward portions of the shells 255 a,255b together when deformed for providing cable strain relief between thecable and the hardened connector 150 as discussed in more detail below.Hardened connectors may also optionally include an insert 250 disposedbetween cable 140 and the rear portions of inner housing 255 forinhibiting damage to the inner housing 255 or providing a secure griponto the cable 140 when deforming crimp band 154. Insert 250 may beformed from any suitably hard material such as a metal or hard polymer.

FIGS. 31 and 32 are close-up rear perspective views of a portion ofshroud 260, cable sealing element 210 and a pusher 220 in an unassembledstate and an assembled state, respectively. The components act to aid insealing the cable entry into the rear portion of hardened connector 150.Generally speaking, the cable sealing element 210 has a passageway 210Pfor receiving cable 140 therethrough and is deformed between the rearend of shroud 260 and the pusher 220 when fully-seated for sealing thecable entry.

To accomplish the sealing, cable sealing element 210 is formed from asuitable material and geometry so that is adequately seals about thecable over the desired temperature range when sufficiently deformed. Byway of example, for outdoor applications the desired temperature rangefor sealing may be −40 to 75° C.; however, other suitable temperatureranges are possible such as for an indoor rated connector or ahigh-temperature rated connector.

Examples of materials for the cable sealing element 210 may be siliconeor other rubber-like sealing materials that may be suitably elastic andhave the desired material properties. For instance, it may be desirableto choose a material for the cable sealing element 210 that has asuitable low-compression set and flexibility over a wide range oftemperatures. Porosity of the cable sealing element material or otherfeatures may provide other desirable features to maintain the sealingover the desired temperature range and lifespan of the hardenedconnector.

In this embodiment, shroud 260 has a chambered end 260C that receivescable sealing element 210 therein along with a longitudinal passageway(not numbered) for receiving the cable 140 therethrough. Thelongitudinal passageway of shroud 260 may have a shape that is tailoredto the outer profile of the cable 140 to aid in the area that must besealed. Chambered end 260C has a threaded portion 260T with a pluralityof flat portions 260F; however, other variations are possible. Each flatportion 260F of shroud 260 has a lug or protrusion 260L that cooperateswith the latch or window 220L on pusher 220 for aligning and initialengagement of the pusher 220 with the rear portion of the shroud 260.

Pusher 220 comprises a longitudinal passageway 220P for receiving cable140 therethrough. Longitudinal passageway 220P may be tailored to theouter profile of cable 140 as desired. Pusher 220 also has one or morearms 220A that cooperate with shroud 260. Pusher 220 also includes aprotrusion portion 220P that extends into the chambered end 260C ofshroud 260. Consequently, when assembled, the cable sealing element 210is trapped between the chambered end 260C and the protrusion portion220P that is snap-fitted to shroud 260 using the engagement between thelatch 220L on pusher 220 and the lugs 260L on shroud 260 as depicted inFIG. 32. The geometry and materials can be advantageously selected sothat the cable 140 may still be easily inserted through the pusher 220,cable sealing element 210 and shroud 260 during initial engagement asshown in FIG. 32, but still provide adequate is sealing when the pusheris fully-engaged during assembly.

FIG. 33 is a perspective view of another cable sealing element 210′ withpassageway 210P that may be used with hardened connector 150 for sealingcable 140. Hardened connector 150 may accommodate other cable profilesor types by using cable sealing elements with passageways having othershapes or outer profiles for cable sealing. Likewise, the passageway ofthe pusher 220 or the rear passageway of shroud 260 may be modified toaccommodate other cable profiles or types as desired. Further, thegeometry of the protrusion portion 220P of pusher 220 and/or thegeometry of the chambered portion 260C of shroud 260 may be modified forother cable profiles of types as desired. By way of explanation, thegeometry or shapes could be adapted for sealing a round cable using thecomponents. Further, round cables could have other constructions forsecuring tensile elements such as aramid yarns such as securing at leastone of the plurality of tensile elements of the cable between an outerbarrel formed by the at least two shells and a crimp band such asdepicted in FIG. 17.

Using the cable sealing element 210, pusher 220 and shroud 260advantageously allows pre-assembling a plurality of components for usein a bag of parts for the hardened connector, thereby simplifying theassembly of the connector by the user. FIGS. 34A-34C are perspectiveviews depicting a pre-assembly of a plurality of parts for forming apre-assembly of components 300 (FIG. 34C) for hardened connector 150,thereby allowing the user to quickly and easily terminate a cable to theconnector using the pre-assembly of components 300. FIG. 34D is apartial sectional view of the pre-assembly of components 300 of FIG. 34Cshowing the arrangement of the pre-assembly components with cableattached 140 thereto and cable sealing member 210 deformed by pusher220.

FIG. 34A depicts an exploded view of an explanatory pre-assembly ofcomponents 300. Other pre-assembly of components according the conceptsdisclosed may include fewer or more components as desired or havedifferent constructions. FIG. 34B depicts the O-ring 159 and couplingnut 164 attached to the shroud 260 as depicted. Coupling nut 164 may usea keeper such as a snap-ring or the like to inhibit it from slidingrearward while still allowing rotation of the coupling nut 164 about theshroud 260 for engaging the threads with a complimentary device such asa receptacle or the like. If used, the snap-ring could sit in anappropriate sized and positioned groove in the shroud and cooperate withthe coupling nut 164. FIG. 34B also shows that cable sealing element 210can be positioned at the rear end of shroud 260 and then pusher 220 maybe attached to the rear end of shroud 260. Thereafter, rear nut 230having an internal threaded portion (FIG. 34D) can be loosely attachedto the rear end of shroud 260 by engaging threads 260T disposed onshroud, thereby forming the pre-assembly of components 300. By looselythreading rear nut 230 onto shroud 260, the cable sealing element 210 isnot appreciably deformed so that the cable 140 may be easily threadedonto cable 140 for quick assembly and termination by the user. FIG. 34Ddepicts rear nut 230 fully-seated to pusher 220 until a shoulder 230S ofrear nut 230 contacts pusher 220 inhibiting further tightening of rearnut 230, thereby deforming cable sealing element 210 so that a suitablecable seal is formed. Consequently, the user can adequately seal thecable 140 to hardened connector 150 without the use of an epoxy or otherlike material, thereby making the field-termination of hardenedconnector quick, simple and reliable. Pusher 220 may comprise areverse-funnel geometry at the rear portion as represented by the dashedlines depicted in FIG. 34D for cable bend-relief; however, otherstructures or components are also possible for providing cablebend-relief at the rear of the hardened connector.

Illustratively, FIG. 35 is a top view of another explanatory cableassembly 100″ with hardened connector 150 similar to FIG. 18 thatfurther includes a boot 166 made of a suitable material for providingcable bend-relief. FIGS. 36A and 36B are longitudinal sectional views ofthe cable assembly 100″ showing the details of the design, which issimilar to cable assembly 100′.

Also disclosed are methods of terminating hardened connectors 150according to the concepts disclosed. FIGS. 37A-37E are perspective viewsshowing the assembly steps of the cable assembly of FIG. 35. Thenecessary parts of the hardened connector may be threaded onto the cable140 in the correct order. As shown in FIG. 37A, boot 166, pre-assembledcomponents 300 and crimp band 154 are threaded onto cable 140. The endportion of cable 140 is prepared for attachment to a mechanical spliceconnector assembly 152 as known in the art such as by removing asuitable portion of the cable jacket 148 to expose the tensile elements144 and optical waveguide 146 of the cable 140 as depicted. Onceexposed, the optical waveguide 146 may be stripped of its coatings andcleaved to an appropriate length for the desired mechanical spliceconnector assembly 152. FIG. 37B depicts the mechanical splice connectorassembly 152 after being optically coupled to the optical waveguide 146of cable 140 for making the mechanical splice between optical waveguide146 and the stub fiber 152 c of the mechanical splice connector assembly152. FIG. 37C depicts the cable 140 and mechanical splice connectorassembly 152 attached to the inner housing 255 comprising shells 255 a,255 b.

FIG. 37D depicts the crimp band 154 being slid forward about the rearportion of inner housing 255 and being secured thereto by beingdeformed. In this embodiment, deforming the crimp band 154 pushes therear portions of the shells 255 a,255 b together for squeezing the rearportions of the shells 255 a,255 b together about and closing the gap G,thereby clamping the shells to the tensile elements 144 of cable 140such as GRP strength components, thereby strain-relieving the cable 140to the inner housing 255. Thereafter, the pre-assembly of components 300may be slid forward onto the inner housing 255 as depicted in FIG. 37E.In this embodiment, shroud 260 comprises a structure for securing theinner housing 255 with shroud 260 for inhibiting excessive movement.Specifically, shroud 260 comprises one or more securing features 260Wthat secure the inner housing 255 to the shroud 260 (or the pre-assemblyof components 300 including shroud 260). More specifically, innerhousing 255 has inner housing locking feature 255L that are securedcooperate with securing feature 260W such as windows as depicted;however other geometries for securing the inner housing 255 with shroud260 are possible. After sliding the pre-assembly of components 300forward to secure it to the shroud, the rear nut 230 is still looselyengaged and does not significantly deform the cable sealing element 210.Consequently, the rear nut 230 can be threaded tighter onto shroud 260advancing pusher 220 forward until the cable sealing element 210 isadequately deformed. FIG. 37F is a sectional view showing the rear nut230 tightened onto shroud 260 showing the advancement of the pusher 220to deform the cable sealing element 210 about the cable 140, therebysealing the cable 140 to the hardened connector 150.

Many modifications and other embodiments of the present invention,within the scope of the appended claims, will become apparent to askilled artisan. Additionally, the present invention can include othersuitable configurations, hybrid designs, structures and/or equipment.Therefore, it is to be understood that the invention is not limited tothe specific embodiments disclosed herein and that modifications andother embodiments may be made within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation. Theinvention has been described with reference to drop cables having FTTxapplications, but the concepts disclosed are applicable to othersuitable applications.

That which is claimed:
 1. A hardened connector, comprising: an innerhousing comprising at least two shells, the at least two shells having alongitudinal passageway for passing at least one optical waveguidetherethrough, at least one cable clamping portion, and a connectorassembly receiving portion, and the connector assembly receiving portioncomprises an extended length cavity; and a mechanical splice connectorassembly, the mechanical splice connector assembly comprises a connectorbody and a ferrule assembly having a stub to optical fiber secured to aferrule, wherein a portion of the mechanical splice connector assemblyis secured to the inner housing so that the ferrule assembly of themechanical splice connector assembly can move rearward into the extendedlength cavity when displaced rearward.
 2. The hardened connector ofclaim 1, the mechanical splice connector assembly comprising one or moresplice parts disposed in a ferrule holder.
 3. The hardened connector ofclaim 1, the mechanical splice connector assembly comprising a cam. 4.The hardened connector of claim 3, the connector assembly receivingportion of the at least two shells shaped to receive the cam of themechanical splice connector only when the cam is in a clampingorientation.
 5. The hardened connector of claim 1, the mechanical spliceconnector assembly comprising one or more translucent components.
 6. Thehardened connector of claim 1, the inner housing comprising at least onelatch for securing the connector body.
 7. The hardened connector ofclaim 1, further including a shroud, wherein a portion of the at leasttwo shells is disposed within the shroud.
 8. The hardened connector ofclaim 1, further comprising a shroud, wherein a portion of the at leasttwo shells is disposed within the shroud and the shroud has a keyedpassageway for inhibiting rotation between the shroud and the at leasttwo shells.
 9. The hardened connector of claim 1, further comprising ashroud with a first finger and a second finger, wherein a portion of theat least two shells is disposed within the shroud, and the shroud has akeyed passageway for orientating the connector housing in apredetermined orientation relative to the first finger and secondfinger.
 10. The hardened connector of claim 1, further including a crimpband for holding the at least two shells together.
 11. The hardenedconnector of claim 1, the at least one hardened connector furthercomprising a shroud having a first end and a second end, and a couplingnut for removably attaching the at least one hardened connector.
 12. Thehardened connector of claim 11, the shroud defining at least one openingof the first end, the at least one opening extending lengthwise from amedial portion of the shroud to the first end of the shroud, wherein theferrule is accessible within the first end of the shroud.
 13. Thehardened connector of claim 12, the at least one opening defining a pairof openings disposed on opposites sides of the shroud.
 14. The hardenedconnector of claim 7, further comprising an O-ring disposed on theshroud for weatherproofing the hardened connector.
 15. The hardenedconnector of claim 1, further comprising a snap ring 163 disposed on aportion of a shroud.
 16. The hardened connector of claim 1, the at leastone hardened connector further comprising a shroud having a first endand a second end, wherein the shroud has at least one alignment indiciafor indicating a mating orientation.
 17. The hardened connector of claim1, further comprising a shroud having a first end and a second end, theshroud includes a first finger and a second finger for mating, whereinthe first finger and the second finger have different cross-sectionalshapes for keying the hardened connector.
 18. The hardened connector ofclaim 1, further comprising a protective cap.
 19. The hardened connectorof claim 1 being attached to a fiber optic cable, the cable furtherincluding a first strength component and a second strength component.20. The hardened connector of claim 1 being attached to a fiber opticcable and further comprising a heat shrink tube for weatherproofing thecable, the heat shrink tube being disposed over a portion of the atleast one hardened connector and a portion of a cable jacket.
 21. Thehardened connector of claim 1 being attached to a fiber optic cable, theat least one cable clamping portion securing at least one of theplurality of tensile elements of the cable between an outer barrelformed by the at least two shells and a crimp band.
 22. The hardenedconnector of claim 1, wherein the at least two shells are at leastpartially disposed within a shroud, the shroud includes a first fingerand a second finger for mating with a complementary receptacle, whereinthe first finger and the second finger are disposed about 180 degreesapart and have different cross-sectional shapes for keying the hardenedconnector.
 23. The hardened connector of claim 1, a plurality of thecomponents of the at least one hardened connector being formed from a UVstabilized material.
 24. A hardened connector, comprising: an innerhousing comprising at least two shells, the at least two shells having alongitudinal passageway for passing at least one optical waveguidetherethrough, at least one cable clamping portion, and a connectorassembly receiving portion, and the connector assembly receiving portioncomprising an extended length cavity; and a mechanical splice connectorassembly, the mechanical splice connector assembly comprises a connectorbody and a ferrule assembly having a stub optical fiber secured to aferrule and one or more splice parts disposed in a ferrule holder,wherein a portion of the mechanical splice connector assembly is securedto the inner housing so that the ferrule assembly of the mechanicalsplice connector assembly can move rearward into the extended lengthcavity when displaced rearward.
 25. The hardened connector of claim 24,the mechanical splice connector assembly comprising a cam.
 26. Thehardened connector of claim 24, the connector assembly receiving portionof the at least two shells shaped to receive the cam of the mechanicalsplice connector only when the cam is in a clamping orientation.
 27. Thehardened connector of claim 24, the mechanical splice connector assemblycomprising one or more translucent components.
 28. The hardenedconnector of claim 24, the inner housing comprising at least one latchfor securing the connector body.
 29. The hardened connector of claim 24,further comprising a snap ring 163 disposed on a portion of a shroud.30. The hardened connector of claim 24, further including a shroud,wherein a portion of the at least two shells is disposed within theshroud.
 31. The hardened connector of claim 24, further comprising ashroud, is wherein a portion of the at least two shells is disposedwithin the shroud and the shroud has a keyed passageway for inhibitingrotation between the shroud and the at least two shells.
 32. Thehardened connector of claim 24, further comprising a shroud with a firstfinger and a second finger, wherein a portion of the at least two shellsis disposed within the shroud, and the shroud has a keyed passageway fororientating the connector housing in a predetermined orientationrelative to the first finger and second finger.
 33. The hardenedconnector of claim 24, further including a crimp band for holding the atleast two shells together.
 34. The hardened connector of claim 24, theat least one hardened connector further comprising a shroud having afirst end and a second end, and a coupling nut for removably attachingthe at least one hardened connector.
 35. The hardened connector of claim34, the shroud defining at least one opening of the first end, the atleast one opening extending lengthwise from a medial portion of theshroud to the first end of the shroud, wherein the ferrule is accessiblewithin the first end of the shroud.
 36. The hardened connector of claim35, the at least one opening defining a pair of openings disposed onopposites sides of the shroud.
 37. The hardened connector of claim 30,further comprising an O-ring disposed on the shroud for weatherproofingthe hardened connector.
 38. The hardened connector of claim 24, the atleast one hardened connector further comprising a shroud having a firstend and a second end, wherein the is shroud has at least one alignmentindicia for indicating a mating orientation.
 39. The hardened connectorof claim 24, further comprising a shroud having a first end and a secondend, the shroud includes a first finger and a second finger for mating,wherein the first finger and the second finger have differentcross-sectional shapes for keying the hardened connector.
 40. Thehardened connector of claim 24, further comprising a protective cap. 41.The hardened connector of claim 24 being attached to a fiber opticcable, the cable further including a first strength component and asecond strength component.
 42. A hardened connector, comprising: aninner housing comprising at least two shells, the at least two shellshaving a longitudinal passageway for passing at least one opticalwaveguide therethrough, at least one cable clamping portion, and aconnector assembly receiving portion, and the connector assemblyreceiving portion comprises an extended length cavity; and a mechanicalsplice connector assembly, the mechanical splice connector assemblycomprises a connector body and a ferrule assembly having a stub opticalfiber secured to a ferrule, one or more splice parts disposed in aferrule holder and a cam, wherein a portion of the mechanical spliceconnector assembly is secured to the inner housing so that the ferruleassembly of the mechanical splice connector assembly fits within theextended length cavity only with the cam orientated in a clampingorientation and the ferrule assembly can move rearward into the extendedlength cavity when displaced rearward.
 43. The hardened connector ofclaim 42, further comprising a snap ring disposed on a portion of ashroud.